Waste Co-processing in Cement Kilns

Transcription

1 Waste Co-processing in Cement Kilns A demonstrated solution for managing wastes in an Environmentally sound and Ecologically sustaining manner Ulhas Parlikar Director Geocycle Business 2012 Holcim/Switzerland Growth, Waste & Environment : Population Economy 2 1

2 How much waste is getting treated Hazardous Waste (Land fillable) Landfill capacity Million Tonnes /year Generation Million Tonnes/ year. Hazardous Waste (Incinerable) Landfill capacity TPA Generation TPA Industrial Waste (Non Hazardous) Generation -??????? TPA Treatment capacity -????????? Municipal Solid Waste Generation >40 Million TPA ALMOST EVERY THING THAT WE GENERATE!!!!!!!!!!!!!!! 3 What does it mean???????????? We are not able to conserve about 8-10 Million TPA of Coal. We are not able to conserve about 8-10 million TPA of natural resources such as lime, iron, silica, alumina etc. We are not able to provide an ecologically sustaining solution for management of different kinds of wastes. We are resorting to disposal options that locks up precious land for any further use, makes us spend large amount of expensive fuels and whose cost of implementation keeps on increasing with time. Government, Waste generator and Solution provider carry large amount of liability towards refurbishment of damage to the landfill. High level of carbon footprint on account of increase in the GHG emissions. Ever increasing backyard volumes and associated environmental hazards 4 2

3 Is there a workable alternative??? Avoid Reduce, Recycle and Recover Co-processing Incineration & Landfill Dumping 5 Co-processing Addressing Sustainability Issues Decreases (largely) the costs of waste management Regional job creation in waste collection and pretreatment etc. Zero-emission technology Leads to fewer landfills and reduces pollution caused by dumping Reduces greenhouse-gas emissions, thereby fighting global warming Reduces the environmental impact of extraction (mining/quarrying), transporting and processing of raw material Conserves natural (non-renewable) energy and material resources 3

4 Mechanism of Waste Management Through Coprocessing In Cement Kiln The organic constituents are completely destroyed due to high temperatures, long residence time and oxidizing conditions in the cement kiln. Acid gases such as HCL and SO 2 are absorbed and neutralized by the freshly formed lime and other alkaline materials within the kiln. The inorganic constituents react with the raw materials while heavy metal becomes immobilized in clinker matrix Geocycle: Exploring a greener waste management pathway through cement kilns Geocycle is an environmental management initiative of Holcim It was recognized that the challenge of increasing waste volumes on one hand and fast depletion of natural resources on the other hand can be addressed through innovative green thinking of co processing wastes as Alternative Fuels and Raw materials in the cement kilns ACC Limited and Ambuja Cement Ltd. are the two group companies of Holcim. They have taken up this Geocycle initiative in the country for providing waste management solutions for achieving green transition in our economic development This initiative solves a growing problem of waste management by encouraging the philosophy of industrial ecology. Wastes from industries or society which would otherwise have been disposed through, dumping, land filling or incineration without any resource/energy recovery are safely co-processed in our cement kilns. WASTE RESOURCE 8 4

5 Geocycle India : Initiatives for Safe Waste Co-processing Establishment of Laboratories & facilities for assessing co process ability and acceptability of wastes Collection of safety data and preparation of relevant safety documents for all wastes co-processed Waste Pre - processing Processe d Waste Designing safety in operations with required precautions during waste transportation, use of right PPEs, relevant safety trainings to personnel handling waste Implementation of Pre-processing platforms Emission concerns during Co processing Emission results of ten co processing trials are evaluated. CPCB defined Trial protocol was used for emission monitoring. (Pre processing 1 day, Co processing 3 days, Post co processing 1 day). Emissions monitored Particulate matter, SOx, NOx, HCl, HF, TOC, Heavy Metals, Dioxin / Furans Emission monitoring from the cement kiln stack was carried out by two CPCB approved agencies. Seven different types of waste streams were used representing five industrial sectors Engineering, Steel, Chemicals, FMCG & Pharma Trials carried out in five different Cement plants. 10 5

6 Particulate Matter 11 SOX, Nox, HCL & HF 12 6

7 Heavy Metals and TOC 13 Dioxin/Furan 14 7

8 Illustrative Examples of wastes co processed Sludges Expired FMCG products Acid tar deposit Plastic waste Organic residue Recalled toys Journey so far TSR YTD Oct More than 5 Lakhs ton of AFR utilized More than 1400 industries mapped More than 2000 waste streams evaluated for co processing acceptance. 125 long term agreements signed 126 streams are introduced for co-processing. 8

9 Stake Holder Engagement Communication Total of eight stakeholder meets organized in association with CPCB and respective SPCBs More than 150 awareness presentations made in different forums. Volumes Co processed 18 9

10 Different Wastes Preprocessed to AFR Saw Dust Municipal waste Paint Sludge Plastics Tyres Final Product 19 Pre-processing Platforms under implementation ACC Wadi Kymore Madukkarai ACL Ambujanagar Rabriyawas Maratha Bhatapara 20 10

11 Co-processing of wastes shall surely go a long way in turning cement from Grey to Green in the Indian Cement industry